THE BELT RAILWAY COMPANY OF CHICAGO Office of General Manager Transportation General Order No. 2 Effective 12:01 AM, June 1, 1006 May 31, 2006 TO ALL CONCERNED: Purpose of revision: RCL Rules revisions and additions will be consolidated and maintained in one general order. Only one general order in each category will be in effect at a time. Changes, amendments will note the purpose for the change and identify new items, additions and revisions to existing general orders. 40.0 Remote Control Operating Rules & Instructions DESIGNATED ABBREVIATIONS: RC...REMOTE CONTROL RCO...REMOTE CONTROL OPERATOR RCS... REMOTE CONTROL SYSTEM RCA... REMOTE CONTROL AREA RCT...REMOTE CONTROL TRANSMITTER OCU...OPERATOR CONTROL UNIT RSC... RESET SAFETY CONTROL RCL... REMOTE CONTROL LOCOMOTIVE RCZ... REMOTE CONTROL ZONE OPP... OPERATING PARAMETER PROGRAMMER PSP... PULLBACK STOPPING PROTECTION 40.1.0 REMOTE CONTROL OPERATING INSTRUCTIONS 1.1 All employees, who are engaged in the actual operation of remote control equipment are governed by and must have a current copy of these instructions accessible while on duty. Remote Control Operators (RCO) will be issued an Operator s Reference Manual, which governs the operation of a Remote Control System. All rules or instructions contained in other company publications will remain in effect unless specifically exempted in these instructions. 1.2 Job Briefing. Prior to beginning operations with Remote Control Equipment, a job briefing must be held among all crewmembers. All Remote Control crewmembers must be informed and clearly understand which crewmember will be controlling the movement with the OCU, and what tasks are to be performed.
Page 2 1.3 Transfer of RCL. When in control of the Remote Control movement, do not transfer control of the Remote Control Locomotive (RCL) to the other RCO until you are ready for movement of the equipment. 1.4 DELETED. Superseded by Safety Rule 31.14.6 1.5 Hand-held Radio. Each RCO must have in their possession an operative, holstered hand-held radio equipped with a wired microphone. 1.6 Movements over Road Crossings. Remote Control movements over road crossings at grade are to be considered "shoving" movements, regardless of direction or position of RCL. (Reference GCOR 6.32.1) 1.7 Control of Movement. During Remote Control Operations, the control must always be with the crew member at the leading end of the movement except while coupling tracks in the class yard. When coupling tracks, the crew member that is coupling the cars must be in control while the other crew member protects the point of the movement. The other crew member must notify the controlling crew member when the engine is within 3 car lengths of fouling the lead. 1.8 Head end movements. RCO s MUST insure the route is lined for head end movements by being on the controlling locomotive. If running long hood forward or from a locomotive unit that is not the lead unit, a crew member must be on the point or someone must visually verify that all switches are lined for the movement. 40.2.0 SETUP AND TESTING Before operating the locomotive in the Remote Control Mode, setup the equipment and perform required tests to be certain that the safety feature operation will respond properly to the OCU commands. EACH RCO MUST OBSERVE THE TESTING OF BOTH OCU s. Setting up a locomotive for remote operation requires the following five main steps: Ensure Hand Brake is applied Setup the control stand Setup the electrical control panel and cabinet Setup the trainline air (if necessary) Setup the remote equipment 2.1 Control Stand. Setup the control stand in the following steps: Turn on radio, set to the required channel ensuring that the portable Radios are on the same channel. Set the automatic brake valve to HANDLE OFF position Set the automatic brake valve cutout valve to OUT position Set the independent brake handle to FULL APPLICATION position Turn the MU-2A valve to TRAIL (Out) position Set both front and back Headlight controls to DIM position
Page 3 Place the throttle in IDLE position Remove the reverser handle Place the generator field switch in the OFF position Ensure the engine run switch is ON Ensure the control & fuel pump switch is ON 2.2 Electrical Panel. Setup the electrical control panel and cabinet in the following steps: Number, platform and running lights ON Set the MU Headlight switch to appropriate position Move the Isolation switch to RUN position Move the Beltpack breaker to ON 2.3 Trainline. Setup the trainline (if necessary) in the following steps: Connect brake pipe and MU hoses and open angle cocks Connect electrical jumper cable Install the walkway chains 2.4 Remote Equipment. Setup the remote equipment in the following steps: Set Radio Mode selector to appropriate controller position (A, A&B, B) Set changeover switch to Beltpack or remote mode Push the appropriate FREQ key (f1, f2, or f3) All RCL Yard, South Chicago, Industry Assignments and Work Trains starting in the East Yard are required to use frequency Number One. All RCL Hump, Industry Assignments and Work Trains that do not start in the East Yard are required to use frequency Number Two. Push the appropriate assignment key (PROG A or PROG B) Power up the OCU Hold the selected OCU (A or B) in front of the infra-red transceiver within 5 seconds Recover Train Brake from both OCUs (if both A & B are used) Recover Emergency from both OCUs, B first (if both A & B are used) Test both OCUs individually: 1. Test RSC Feature 2. Test Tilt Feature 2.5 Alerter. RSC Test (Alerter): Place the Reverser selector on the OCU in Neutral position. Push the Reset button and immediately move the Speed selector to a Power position. Wait 50 seconds and a pulse tone alarm sounds. After approximately 10 seconds, a RSC fault will occur and a full service brake application then occurs.
Page 4 2.6 Tilt Test Tilt the OCU more than 45 degrees. After 1 second the continuous tone alarm will activate. After approximately 4 seconds a Tilt time out fault occurs. An emergency brake application then occurs. To return to operation, return the OCU to upright position and recover Emergency from the OCU. 2.7 Testing Equipment. When to Test Equipment Perform a full RSC and TILT Test when initially setting up the equipment for remote operation. When relieving a previous Beltpack Crew and the system has remained in Beltpack mode, perform a full Beltpack test but only check the OCU TILT and RSC safety features until the alarms are heard. Operators do not need to observe each other s test. If an OCU becomes inoperative during a shift, and an OCU is replaced, a full RSC and TILT test must be performed. Both operators do not need to observe this test. Release hand brake on Locomotive and perform a running brake test. 2.8 A Operator. During Remote Control Operations, the senior crew member must link up as the A operator. Remote Control Tag - (new) Each locomotive in the remote control consist must have a tag placed on the control stand, over the locomotive horn handle, throttle, or reverse lever, indicating the locomotive is being used in a remote control mode. The tag must be removed when the locomotive is placed in manual mode. Laminated tag reads: WARNING Locomotive in Remote Control. 40.3.0 OPERATING THE EQUIPMENT 3.1 Qualified Operator. Only qualified operators or students who have been trained in Remote Control operations may operate an OCU. 3.2 Control of RCL Consist. An RCO shall control only one RCL consist at a time with an OCU and shall not operate any other RCL or manual mode locomotive simultaneously. 3.3 Automobiles. An RCO must not operate an RCL while in a moving or stopped automobile. 3.4 Performance of Duties. Both employees of an RCO crew must wear their OCU at all times in the performance of duties.
Page 5 3.5 Pitch and Catch. Changing control of the Beltpack locomotive from one operator to the other is called Pitch and Catch. Change control of operators as follows: Bring movement to a stop. Set both OCUs to Stop position on the Speed selector. Set both OCUs to the same Train Brake selector position. Within 10 seconds of the Pitch command, the receiving (catching) operator presses the Reset (RSC) button. To verify control has transferred you may press the Status button. The corresponding Talker message will give locomotive number followed by the OCU letter (i.e. BRC 581 A or BRC 581 B). Ensure all crewmembers understand which operator is controlling movement. Note: To cancel a Pitch, the controlling operator need only make a command before the other operator catches control (i.e. presses the RSC button). 3.6 OCU Fasteners. When the remote control operator secures the Operator Control Unit (OCU) to his vest, the OCU must be fastened, with the approved fasteners, at all four points. 3.7 Tilt Message. In the event an OCU tilt time out unsolicited message is heard, excluding messages heard during start up tests, immediate action must be taken to find out if the operator who caused the tilt fault is ok. During yard and hump operations, a crew member will be responsible for contacting the operator who caused the tilt fault. The yardmaster/humpmaster will also be responsible for contacting the operator. If the operator who caused the tilt fault does not immediately respond, the yardmaster/humpmaster will be responsible for stopping all movement in the yard/hump and taking the proper emergency actions. During Industry, work train, and boat job assignments, a crew member will be responsible for contacting the operator who caused the tilt fault to determine the operator s condition and status. 3.8 Disabled Devices. Employees are prohibited from knowing using a remote control transmitter with a disabled safety. 3.9 Lite Locomotives. The operator must take a position on the leading end of a lite remote control locomotive consist or be positioned on the ground clear of the movement and able to observe the entire movement before initiating the movement. 40.4.0 SECURING REMOTE CONTROL EQUIPMENT 4.1 Spare OCU. Spare OCUs must not be stored either while set up (linked to) or while communicating with a RCL. 4.2 Unattended Equipment. When leaving equipment unattended for during set up or during short periods (meal, securing paperwork, etc) the RCO must secure the RCL by turning off Both OCUs, set the hand brake on the locomotive(s) and place the locomotive isolation switches in the isolate position.
Page 6 4.3 Going off Duty. When going off duty the RCO must secure the RCL by turning off Both OCUs, set the hand brake on the locomotive(s) and place the locomotive isolation switches in the isolate position. In addition, complete all steps to return the locomotive to the Lead Manual mode setup and comply with current Locomotive securement rules. 40.5.0 OPERATING PROCEDURES - General 5.1 Assignment of OCU. BeltPack OCU s will be assigned to a crew by the Yardmaster on duty. The Yardmaster will record the number of the OCU issued to each crew member in the OCU Management Program. The number is on the bottom of the OCU. The OCU s will be issued and returned to the Yardmaster inside the Yardmaster s Office in clear view of the security camera in the office. It is the Yardmaster s responsibility to keep the OCU s inside the Yardmaster s Office until issued to the next RCO. South Chicago Boat Assignments must report OCU information to the diesel shop foreman at the beginning and end of each shift. The information must include: employee name, date, time on/off duty and the identification number on the bottom of the OCU. Also, report the general condition of the OCU including any damage to the unit. The diesel shop foreman will enter the information in the OCU Management System. If the diesel shop foreman does not answer, the phone will go to voice mail and the information may be left in a recorded message. RCL equipment, OCU s, and any other equipment associated with BeltPack Operation are considered safety devices and must not be tampered with under any circumstances. 5.2 Batteries. Each shift will be required to use designated OCU batteries in the Classifications Yards and on the Hump. White batteries will be designated to the morning shift. Yellow batteries will be designated to the afternoon shift Red batteries will be designated to the night shift. RCO operators are to use ONLY the colored battery designated to their shift. Spare batteries will be available to each shift if needed. 5.3 Locomotive Inspection. FRA Regulations require locomotives that are in service to be inspected each calendar day (Reference ABTH Rule 112). To ensure compliance, the first employee (RCO, Engineer or other Inspector) taking charge of a locomotive after 12:01AM must: Conduct the required locomotive inspection. After inspection is completed, fill out the white daily inspection card.
Page 7 The First Section of the Calendar Day Inspection Report will contain the locomotive number and the date the locomotive must be in the shop for the next FRA locomotive inspection. The Second Section is for the RCO or Engineer who starts a shift after 12:01AM. This section must be filled out with the date, the location where the locomotive was inspected and time of the inspection. If the locomotive was not used in a calendar day, the RCO or Engineer will enter that date and location. In the time section, enter NOT USED for the previous day and then enter the current information on the next line. The Third Section is for the RCO or Engineer to print their name and employee number; list any defects (if there are no defects, put None ) and the person the defect has been reported to. The Fourth Section is for the Diesel Shop, leave this section blank. 5.4 Flat Spots. To eliminate flat spots on wheels, RCO s must refrain from stopping with the independent brake override (except in an emergency). 5.5 Cleaning Switches. When required to clear switches of snow and ice when operating in remote control, it will be necessary for crews to follow these procedures: The hose on the air wand found on the locomotives must be connected to the brake pipe. Place the Reverser on the Operator Control Unit (OCU) in neutral position. Place the Automatic Train Brake selector on OCU in the charge position. While holding the wand firmly, open the angle cock on the brake pipe, and then open the angle cock on the air wand, at this point or shortly after, the diesel engine on the locomotive will increase to maximum RPM, thus maintaining brake pipe pressure. Leave the Automatic Train Brake selector on the OCU in the charge position until the switch is cleared. This will ensure that the diesel engine will maintain maximum RPM. Once switch is cleared, resume normal operating procedures. 5.6 Snow Brake Feature. Each RCL is equipped with a snow brake feature. When required to activate the snow brake, the following procedures will apply: Press the snowflake button on the Operating Parameter Programmer (OPP) Station keypad and ensure that the LED above the small snow flake is on. To deactivate, press the snowflake button on the keypad and ensure that the LED above the small snow flake is off. Note: When the snow brake feature is activated, a brake cylinder pressure of 6 P.S.I. will be maintained with the brakes released. This will aid in preventing a build up of snow and ice between the wheels and brake shoes on the locomotive.
Page 8 5.7 Over-riding PSP. Procedure for Overriding Pullback Stopping Protection (PSP): PSP Override mode is engaged by pressing the <<Menu>> button on the OPP console and pressing the <<OK>> button when PSP Override is displayed. The OPP will then ask you to press the Bell button on the controlling or the non-controlling OCU within 5 seconds to confirm the PSP Override. Note: Hump Engines are NOT equipped with PSP. 5.8 Bad Order OCUs. All Bad Ordered OCU s are to be given exclusively to the Trainmaster or Diesel Shop Foreman on duty, RCO Supervisor or designated RCO Troubleshooter. OCU must be tagged and defect noted on the tag. 5.9 Verification of PSP. The RCL operator must verify the PSP is working before depending on the PSP to stop the movement. On the initial movement into the PSP limits the RCO operator must monitor the remote control transmitter message to verify the PSP is functioning as intended. 5.10 Overriding PSP. Point protection is required when RCO manually overrides the PSP equipment. 40.6.0 OPERATING PROCEDURES - Hump 6.1 Pitch Control. Pitching control instructions for the Hump While working on the hump, crew members must inform each other which direction the locomotive is facing when pitching control to each other. When sending the locomotive down an Approach to the other crew member; the crew member pitching control must let the crew member receiving control know that the locomotive is moving in the right direction. 6.2 Trainline Air. During hump operations, trains must have air cut into 10% of the train for added braking power prior to humping. 6.3 Heavy Trains. When required to hump heavy trains with remote control equipment, it will be necessary for crews to follow these procedures to avoid LIFT FAULTS or SPEEDOMETER FAULTS: LIFT FAULTS: When ready to begin humping train, Move the SPEED SELECTOR LEVER to MAXIMUM position. Depress and hold either of the R.S.C. buttons, this will apply sand as necessary. Release once the train is moving. Once the train is moving immediately select desired hump speed.
Page 9 Note: If the SPEED SELECTOR LEVER is ramped down too rapidly, the brakes on the locomotive will apply and stop the movement. Should this occur, the above procedures should be repeated. SPEEDOMETER FAULTS: When humping, if the train must be stopped, the operator should move the AUTOMATIC BRAKE SWITCH (train brake) to either the LIGHT or MEDIUM position and at the same time, place the SPEED SELECTOR LEVER in the Stop position. This should prevent excessive roll-back of the train thus reducing the likelihood of a SPEEDOMETER FAULT event. Once train movement has stopped rolling back, release the automatic brake. When instructed to begin humping, follow the procedures required to prevent LIFT FAULTS. Note: As train length and tonnage decrease while humping, crews should revert to normal humping procedures. 40.7.0 SPECIAL OPERATING PROCEDURES - Yards 7.1 Pulling Trains. When pulling trains from both East and West Classification Yards, an RCO must not be in excess of 250 feet ahead of movement and must comply with GCOR 6.28 (Movement on Other than Main Track). 7.2 Speed, Throat of Yards. Within the throat of the East and West Yards, no RCL is allowed to exceed 4 MPH. The West Yard throat is defined as the area between the west clearance points of any track in the West Classification Yard to the east clearance point of any track in the West Departure Yard. The East Yard throat is defined as the area between the east clearance point of any track in the East Classification Yard to the west clearance point of any track in the East Departure Yard. 7.3 DELETED: Breaks. 7.4 Making Repairs. When Mechanical forces are making repairs in the classification yards, the following procedure must be followed. The respective Yardmaster (East/West Yard) must insure that the track or tracks are blocked out with the hump prior to anyone entering the track. An RCO working with a Carmen who is making repairs must first separate the cars by no less than 100 Feet. Once the cars are separated, Three Point Protection must be provided prior to the Carmen fouling the track. Once Three Point Protection is confirmed by the Carmen, A small Blue Light will be handed to the controlling RCO. The RCO holding the Blue Light will be responsible for the following until the work is completed and the Blue Signal protection is removed:
Page 10 Stay with the Carmen until such work is completed. Maintain control of the locomotive. Do NOT pitch control to another crew member until the blue signal protection is removed. The RCO must hold this Blue Light and not operate any controls on the OCU until the Carmen completes the work and takes back control of the Blue Light. Only when the Blue Signal protection is removed can the locomotive be moved. 7.5 DELETED: Train Length Restriction 40.8.0 OPERATING PROCEDURES - Industry Assignments and Work Trains 8.1 Air Brake Tests Main Track. Industry assignments and work trains operating on the Main Track outside Clearing Industrial District are required to perform a Transfer Train Brake Test as follows: a) The air brake hoses must be coupled between all cars. b) The brake system is charged to no less than 60 psi as indicated by an accurate gauge or end-of-train device at the rear of the train. Charge the brake system to no less than 75 psi in remote operation. c) Make a 15 psi service brake pipe reduction. Use a MEDIUM train brake setting on the OCU in remote operation. d) Brakes must apply on all cars and stay applied for 3 minuets. Point of origin transfer test requires 100% operative brakes. Transfer test other than point of origin requires 85% operative brakes. Any cars found with brakes not applied must be set out and repaired before leaving the yard. When cars are added to the train in route these cars must be tested in the same manner as above, except that any cars with brakes that fail to apply must be noted on the Conductor s paperwork and reported to the Car Foreman when returning to the yard. These cars must be repaired before leaving the yard. The air gauges required for the air test will be issued with the crew s paperwork and Nextel phone and all are to be turned in at the end of their tour of duty. 40.9.0 OPERATING PROCEDURES - Boat Jobs 9.1 Instructions. When reporting for duty, contact the MTO for a job briefing. KCBX will fax a line up of what is to be done. Upon receiving the fax contact the KCBX crew leader for further instructions. When starting a train, the first pull from Commercial yard will be 48 cars. Set the 48 cars on KCBX approaches approximately 14 to 16 cars per track. Secure each track
Page 11 with two (2) handbrakes. Remember, the crew member at the leading end of the movement must be in control. Next, pull the loop, if needed, and put the cars in the J yard. Then go up to Commercial Yard and get the rest of the train. Spot cars on KCBX Approach, if needed, and put the rest of the train in the J yard. If the train is going to be left on the Fence track, the train must be secured according to BRC Rules with five (5) handbrakes. 9.2 Air Brake Test Boat Job. Perform an air brake test before moving cars between Commercial Ave and the District Yard. Use a gauge to determine the charge is not less than 75psi on the rear car. Use the MEDIUM train brake setting on the OCU to apply the brakes. Verify the brakes apply and release on the rear car. It is permissible to pull the empties over the 100 th Street crossing before doing the air test. Air gauges will be in the trailer at 100 th St. M. A. Paras General Manager Transportation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - General Orders In Effect: 1, 2